Kohler Courage SH265 Manual de usuario
1
18 690 01 Rev. A KohlerEngines.com
SH265
Service Manual
2 Safety
3 Maintenance
5 Specications
12 Tools and Aids
15 Troubleshooting
19 Air Cleaner/Intake
20 Fuel System
24 Governor System
25 Lubrication System
26 Electrical System
30 Starter System
34 Disassembly/Inspection and Service
43 Reassembly
IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.
2
Safety
KohlerEngines.com 18 690 01 Rev. A
SAFETY PRECAUTIONS
WARNING: A hazard that could result in death, serious injury, or substantial property damage.
CAUTION: A hazard that could result in minor personal injury or property damage.
NOTE: is used to notify people of important installation, operation, or maintenance information.
WARNING
Explosive Fuel can cause
res and severe burns.
Do not ll fuel tank while
engine is hot or running.
Gasoline is extremely ammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or ames.
Spilled fuel could ignite if it comes
in contact with hot parts or sparks
from ignition. Never use gasoline
as a cleaning agent.
WARNING
Rotating Parts can cause
severe injury.
Stay away while engine
is in operation.
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never
operate engine with covers,
shrouds, or guards removed.
WARNING
Carbon Monoxide can
cause severe nausea,
fainting or death.
Avoid inhaling exhaust
fumes.
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.
WARNING
Accidental Starts can
cause severe injury or
death.
Disconnect and ground
spark plug lead(s) before
servicing.
Before working on engine or
equipment, disable engine as
follows: 1) Disconnect spark plug
lead(s). 2) Disconnect negative (–)
battery cable from battery.
WARNING
Hot Parts can cause
severe burns.
Do not touch engine
while operating or just
after stopping.
Never operate engine with heat
shields or guards removed.
WARNING
Cleaning Solvents can
cause severe injury or
death.
Use only in well
ventilated areas away
from ignition sources.
Carburetor cleaners and solvents
are extremely ammable. Follow
cleaner manufacturer’s warnings
and instructions on its proper and
safe use. Never use gasoline as a
cleaning agent.
CAUTION
Electrical Shock can
cause injury.
Do not touch wires while
engine is running.
CAUTION
Damaging Crankshaft
and Flywheel can cause
personal injury.
Using improper procedures can
lead to broken fragments. Broken
fragments could be thrown from
engine. Always observe and use
precautions and procedures when
installing ywheel.
WARNING
Uncoiling Spring can
cause severe injury.
Wear safety goggles or
face protection when
servicing retractable
starter.
Retractable starters contain a
powerful, recoil spring that is
under tension. Always wear safety
goggles when servicing retractable
starters and carefully follow
instructions in Retractable Starter
for relieving spring tension.
3
Maintenance
18 690 01 Rev. A KohlerEngines.com
MAINTENANCE INSTRUCTIONS
WARNING
Before working on engine or equipment, disable engine as
follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Accidental Starts can cause severe injury or
death.
Disconnect and ground spark plug lead(s)
before servicing.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.
MAINTENANCE SCHEDULE
After rst 5 Hours
● Change oil. Lubrication System
Every 50 Hours or Annually
● Service/replace dual-element precleaner. Air Cleaner/Intake
Every 100 Hours or Annually¹
● Clean low-prole air cleaner element. Air Cleaner/Intake
● Replace dual-element air cleaner element. Air Cleaner/Intake
● Change oil. Lubrication System
● Clean cooling areas. Air Cleaner/Intake
● Clean spark arrestor (if equipped).
● Replace spark plug and set gap. Electrical System
● Replace fuel lter (if equipped).
Every 100 Hours2
● Check and adjust valve clearance when engine is cold. Reassembly
● Have combustion chamber decarbonized.
Every 200 Hours²
● Replace fuel line. Fuel System
Every 300 Hours
● Replace low-prole air cleaner element. Air Cleaner/Intake
1 Perform these procedures more frequently under severe, dusty, dirty conditions.
2 Have a Kohler authorized dealer perform this service.
REPAIRS/SERVICE PARTS
Kohler genuine service parts can be purchased from Kohler authorized dealers. To nd a local Kohler authorized
dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).
4
Maintenance
KohlerEngines.com 18 690 01 Rev. A
OIL RECOMMENDATIONS
We recommend use of Kohler oils for best performance.
Other high-quality detergent oils (including synthetic)
of API (American Petroleum Institute) service class SJ
or higher are acceptable. Select viscosity based on
air temperature at time of operation as shown in table
below.
FUEL RECOMMENDATIONS
WARNING
Explosive Fuel can cause res and severe
burns.
Do not ll fuel tank while engine is hot or
running.
Gasoline is extremely ammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or ames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
NOTE: E15, E20 and E85 are NOT approved and
should NOT be used; effects of old, stale or
contaminated fuel are not warrantable.
Fuel must meet these requirements:
● Clean, fresh, unleaded gasoline.
● Octane rating of 87 (R+M)/2 or higher.
● Research Octane Number (RON) 90 octane minimum.
● Gasoline up to 10% ethyl alcohol, 90% unleaded is
acceptable.
● Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blend (max 15% MTBE by volume) are
approved.
● Do not add oil to gasoline.
● Do not overll fuel tank.
● Do not use gasoline older than 30 days.
STORAGE
If engine will be out of service for 2 months or more
follow procedure below.
1. Add Kohler PRO Series fuel treatment or equivalent
to fuel tank. Run engine 2-3 minutes to get stabilized
fuel into fuel system (failures due to untreated fuel
are not warrantable).
2. Change oil while engine is still warm from operation.
Remove spark plug(s) and pour about 1 oz. of
engine oil into cylinder(s). Replace spark plug(s) and
crank engine slowly to distribute oil.
3. Disconnect negative (-) battery cable.
4. Store engine in a clean, dry place.
5
Specications
18 690 01 Rev. A KohlerEngines.com
369.40
[14.543]
113.44
[4.466]
273.97
[10.786]
88.00
[3.465]
339.90
[13.382]
106.00
[4.173]
30.00
[1.181]
METRIC FLANGE: 4X M8 X 1.25-6H THRU
SAE A FLANGE: 4X 5/16-24 UNF-2B THRU
METRIC FLANGE: 4X M8 X 1.25-6H 15.00 [0.591]
SAE A FLANGE: 4X 5/16-24 UNF-2B 15.00 [0.591]
162.00
[6.378]
342.20
[13.473]
65.05
[2.561]
32.53
[1.281]
66.00 [2.598]
32.53 [1.281]
65.05 [2.561]
318.66
[12.545]
STRAIGHT PTO
181.60
[7.150]
SPARK
PLUG
OIL FILL
DRAIN PLUG
37.98 [1.495]
37.50 [1.476]
78.00
[3.071]
2X Ø 10.00 [0.394]
2X 10.00 X 15.50
SLOT [0.394 X 0.610]
110.00 [4.331]
AIR CLEANER
COVER
REMOVAL
12.50
[0.492]
GAS CAP
REMOVAL
Engine Dimensions
Dimensions in millimeters.
Inch equivalents shown in [ ].
6
Specications
KohlerEngines.com 18 690 01 Rev. A
ENGINE IDENTIFICATION NUMBERS
Kohler engine identication numbers (model, specication and serial) should be referenced for efcient repair,
ordering correct parts, and engine replacement.
Model .....................SH265
Courage Engine
Horizontal Shaft
Numerical Designation
Specication . . . . . . . . . . . . . . . SH265-0001
Serial .....................3923500328
Year Manufactured Code Factory Code
Code Year
39 2009
40 2010
41 2011
GENERAL SPECIFICATIONS3,6 SH265
Bore 68 mm (2.7 in.)
Stroke 54 mm (2.1 in.)
Displacement 196 cc (12.0 cu. in.)
Oil Capacity (rell) 0.6 L (0.63 U.S. qt.)
Maximum Angle of Operation (@ full oil level)425°
TORQUE SPECIFICATIONS3,5 SH265
Air Cleaner
Mounting Screw (into intake manifold) 8 N·m (70.8 in. lb.)
Blower Housing and Sheet Metal
M6 Shoulder Screw 10 N·m (88.5 in. lb.)
M6 Nut 8 N·m (70.8 in. lb.)
Carburetor
Stud 10 N·m (88.5 in. lb.)
Primary Nut 8 N·m (70.8 in. lb.)
Secondary Nut 10 N·m (88.5 in. lb.)
Intake Cover Nut 4 N·m (35.4 in. lb.)
Connecting Rod
Cap Fastener (torque in increments) 12 N·m (106 in. lb.)
Crankcase
Oil Drain Plug 18 N·m (13 ft. lb.)
Closure Plate Screw 24 N·m (212 in. lb.)
Cylinder Head
Fastener (torque in 2 increments) rst to 12 N·m (106 in. lb.)
nally to 24 N·m (212 in. lb.)
3 Values are in Metric units. Values in parentheses are English equivalents.
4 Exceeding maximum angle of operation may cause engine damage from insufcient lubrication.
5 Lubricate threads with engine oil prior to assembly.
6 Any and all horsepower (hp) references by Kohler are Certied Power Ratings and per SAE J1940 & J1995 hp
standards. Details on Certied Power Ratings can be found at KohlerEngines.com.
7
Specications
18 690 01 Rev. A KohlerEngines.com
TORQUE SPECIFICATIONS3,5 SH265
Flywheel
Retaining Nut 74 N·m (655 in. lb.)
Fuel Tank
Mounting Nut 24 N·m (212 in. lb.)
Mounting Screw 24 N·m (212 in. lb.)
Inlet Fitting 1.5 N·m (13.3 in. lb.)
Governor
Arm Nut 10 N·m (88.5 in. lb.)
Throttle Control Lever Nut 4.5-6 N·m (40-53 in. lb.)
Ignition
Spark Plug 27 N·m (20 ft. lb.)
Module Fastener 8 N·m (70.8 in. lb.)
Module Screw 10 N·m (88.5 in. lb.)
Oil Sentry™ Module Screw 8 N·m (70.8 in. lb.)
Mufer
M8 Exhaust Screw 24 N·m (212 in. lb.)
M6 Mufer Shield Screw 8 N·m (70.8 in. lb.)
M4 Mufer Shield Screw 2 N·m (17.7 in. lb.)
M5 Spark Arrestor Screw 3.5 N·m (31 in. lb.)
Retractable Starter
Cover Screw 5.4 N·m (47.8 in. lb.)
Screw 10 N·m (88.5 in. lb.)
Rocker Arm
Stud 13.6 N·m (120 in. lb.)
Pivot Jam Nut 10 N·m (88.5 in. lb.)
Valve Cover
Fastener 8 N·m (70.8 in. lb.)
3 Values are in Metric units. Values in parentheses are English equivalents.
5 Lubricate threads with engine oil prior to assembly.
8
Specications
KohlerEngines.com 18 690 01 Rev. A
CLEARANCE SPECIFICATIONS3SH265
Camshaft
End Play 0.025/0.602 mm (0.0010/0.0237 in.)
Running Clearance 0.016/0.052 mm (0.0006/0.0020 in.)
Bore I.D.
New
Max. Wear Limit
14.000/14.018 mm (0.5512/0.5519 in.)
14.048 mm (0.5531 in.)
Connecting Rod
Crankpin End I.D. @ 21°C (70°F)
New
Max. Wear Limit
30.021/30.026 mm (1.1819/1.1821 in.)
30.08 mm (1.184 in.)
Connecting Rod-to-Crankpin Running Clearance
New
Max. Wear Limit
0.041/0.051 mm (0.002/0.002 in.)
0.12 mm (0.005 in.)
Connecting Rod-to-Crankpin Side Clearance
New
Max. Wear Limit
0.58/0.60 mm (0.023/0.024 in.)
1.10 mm (0.043 in.)
Connecting Rod-to-Piston Pin Running Clearance 0.01/0.027 mm (0.0004/0.0011 in.)
Piston Pin End I.D. @ 21°C (70°F)
New
Max. Wear Limit
18.010/18.015 mm (0.709/0.709 in.)
18.08 mm (0.712 in.)
Crankcase
Governor Cross Shaft Bore I.D.
New
Max. Wear Limit
6.000/6.018 mm (0.2362/0.2369 in.)
6.037 mm (0.2377 in.)
Crankshaft
End Play (free) 0.025/0.703 mm (0.0010/0.028 in.)
Ball Bearing 0.003/0.25 mm (0.0001/0.0010 in.)
Bore (in crankcase)
New, without Main Bearing 51.961/51.991 mm (2.0457/2.0469 in.)
Bore (in closure plate)
New, without Main Bearing 51.961/51.991 mm (2.0457/2.0469 in.)
Flywheel End Main Bearing Journal O.D.
O.D.-New
O.D.-Max. Wear Limit
Max. Taper
Max. Out-of-Round
24.975/24.989 mm (0.9833/0.9838 in.)
24.95 mm (0.9823 in.)
0.025 mm (0.0010 in.)
0.025 mm (0.0010 in.)
Closure Plate End Main Bearing Journal O.D.
O.D.-New
O.D.-Max. Wear Limit
Max. Taper
Max. Out-of-Round
24.975/24.989 mm (0.9833/0.9838 in.)
24.95 mm (0.9823 in.)
0.025 mm (0.0010 in.)
0.025 mm (0.0010 in.)
Connecting Rod Journal O.D.
O.D.-New
O.D.-Max. Wear Limit
Max. Taper
Max. Out-of-Round
Width
29.975/29.985 mm (1.1801/1.1805 in.)
29.920 mm (1.1779 in.)
0.025 mm (0.0010 in.)
0.025 mm (0.0010 in.)
25.02/25.08 mm (0.9850/0.9874 in.)
Runout (either end) 0.025 mm (0.0010 in.)
Main Bearing I.D. (Crankcase/Closure Plate)
New (installed) 24.994/25.000 mm (0.9840/0.9842 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.
5 Lubricate threads with engine oil prior to assembly.
9
Specications
18 690 01 Rev. A KohlerEngines.com
CLEARANCE SPECIFICATIONS3SH265
Cylinder Bore
Bore I.D.
New
Max. Wear Limit
Max. Out-of-Round
Max. Taper
70.027/70.035 mm (2.757/2.757 in.)
70.200 mm (2.764 in.)
12.7 microns (0.0005 in.)
12.7 microns (0.0005 in.)
Cylinder Head
Max. Out-of-Flatness 0.1 mm (0.0039 in.)
Governor
Governor Cross Shaft-to-Crankcase Running Clearance 0.013/0.075 mm (0.0005/0.0029 in.)
Governor Cross Shaft O.D.
New
Max. Wear Limit
5.95/5.98 mm (0.2342/0.2354 in.)
5.85 mm (0.2303 in.)
Governor Gear Shaft-to-Governor Gear Running Clearance 0.09/0.19 mm (0.0035/0.0074 in.)
Governor Gear Shaft O.D.
New
Max. Wear Limit
6.028/6.043 mm (0.2373/0.2379 in.)
6.018 mm (0.2369 in.)
Ignition
Spark Plug Gap 0.76 mm (0.030 in.)
Module Air Gap 0.254 mm (0.0100 in.)
Piston, Piston Rings, and Piston Pin
Piston-to-Piston Pin Running Clearance 0.009/0.016 mm (0.0003/0.0006 in.)
Piston Pin Bore I.D.
New
Max. Wear Limit
18.004/18.005 mm (0.7088/0.7089 in.)
18.05 mm (0.7106 in.)
Piston Pin O.D.
New
Max. Wear Limit
17.992/17.995 mm (0.7083/0.7084 in.)
17.95 mm (0.7067 in.)
Top and Center Compression Ring Side Clearance
New Bore
Used Bore (max.)
0.04 mm (0.002 in.)
0.15 mm (0.006 in.)
Top and Center Compression Ring End Gap
New Bore
Used Bore (max.)
0.325 mm/0.4 (0.013/0.016 in.)
1.00 mm (0.039 in.)
Top and Center Compression Ring Width
New Bore
Used Bore (max.)
1.5/1.51 mm (0.059/0.059 in.)
1.37 mm (0.054 in.)
Oil Control Ring-to-Groove Side Clearance 0.06/0.18 mm (0.0023/0.0071 in.)
Piston Thrust Face O.D.7
New
Max. Wear Limit
67.975/67.985 mm (2.6762/2.6766 in.)
67.85 mm (2.6712 in.)
Piston Thrust Face-to-Cylinder Bore Running Clearance
New 0.057/0.075 mm (0.0022/0.0029 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.
7 Measure 15 mm (0.5905 in.) above bottom of piston skirt at right angles to piston pin.
10
Specications
KohlerEngines.com 18 690 01 Rev. A
CLEARANCE SPECIFICATIONS3SH265
Valves and Valve Lifters
Intake Valve Stem-to-Valve Guide Running Clearance 0.020/0.044 mm (0.008/0.0017 in.)
Exhaust Valve Stem-to-Valve Guide Running Clearance 0.030/0.054 mm (0.0011/0.0021 in.)
Intake Valve Stem O.D.
New
Max. Wear Limit
5.480 mm (0.2157 in.)
5.32 mm (0.2094 in.)
Exhaust Valve Stem O.D.
New
Max. Wear Limit
5.47 mm (0.2153 in.)
5.305 mm (0.2088 in.)
Intake Valve Stem to Guide
New
Max. Wear Limit
0.024/0.039 mm (0.001/0.002 in.)
0.10 mm (0.0004 in.)
Exhaust Valve Stem to Guide
New
Max. Wear Limit
0.098/0.112 mm (0.0038/0.0044 in.)
0.12 mm (0.0005 in.)
Valve Guide Reamer Size
Standard Intake
Standard Exhaust
5.506 mm (0.2168 in.)
5.506 mm (0.2168 in.)
Valve Seat Width 0.800/2.00 mm (0.0315/0.787 in.)
Nominal Valve Face Angle 30°, 45°, 60°
3 Values are in Metric units. Values in parentheses are English equivalents.
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